Improved analytical model for residual stress prediction in orthogonal cutting

doi:10.1007/s11465-014-0310-1

Front. Mech. Eng.

2014, Vol. 9

Issue (3) : 249-256 https://doi.org/10.1007/s11465-014-0310-1

RESEARCH ARTICLE

Improved analytical model for residual stress prediction in orthogonal cutting

Zhaoxu QI,Bin LI,Liangshan XIONG(

)

Department of Mechanical Engineering, Huazhong University of Science & Technology, Wuhan 430074, China

Download: PDF(843 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

The analytical model of residual stress in orthogonal cutting proposed by Jiann is an important tool for residual stress prediction in orthogonal cutting. In application of the model, a problem of low precision of the surface residual stress prediction is found. By theoretical analysis, several shortages of Jiann’s model are picked out, including: inappropriate boundary conditions, unreasonable calculation method of thermal stress, ignorance of stress constraint and cyclic loading algorithm. These shortages may directly lead to the low precision of the surface residual stress prediction. To eliminate these shortages and make the prediction more accurate, an improved model is proposed. In this model, a new contact boundary condition between tool and workpiece is used to make it in accord with the real cutting process; an improved calculation method of thermal stress is adopted; a stress constraint is added according to the volume-constancy of plastic deformation; and the accumulative effect of the stresses during cyclic loading is considered. At last, an experiment for measuring residual stress in cutting AISI 1045 steel is conducted. Also, Jiann’s model and the improved model are simulated under the same conditions with cutting experiment. The comparisons show that the surface residual stresses predicted by the improved model is closer to the experimental results than the results predicted by Jiann’s model.

Keywords residual stress analytical model orthogonal cutting cutting force cutting temperature

Corresponding Author(s): Liangshan XIONG

Online First Date: 02 September 2014 Issue Date: 10 October 2014

Cite this article:

Zhaoxu QI,Bin LI,Liangshan XIONG. Improved analytical model for residual stress prediction in orthogonal cutting[J]. Front. Mech. Eng., 2014, 9(3): 249-256.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-014-0310-1
https://academic.hep.com.cn/fme/EN/Y2014/V9/I3/249

Fig.1 Schematic diagram for ploughing effect. (a) Ploughing effect; (b) Stress distribution of two-dimensional Hertzian contact form; (c) Stress distribution according to Waldorf’s slip-line field model

Fig.2 Flow chart of improved model

Fig.3 Cutting test and the measurement of residual stress. (a) Cutting test equipments; (b) measure equipment of X-press3000 XRD

Tab.1 Cutting test parameters

Tab.2 Constants of Johnson-Cook flow stress model for AISI 1045 steel

Tab.3 Material parameters for AISI 1045

Fig.4 Comparison of simulations and experimental results for the condition of v =100m/min, f =0.1mm/r. (a) X-direction residual stresses; (b) Y-direction residual stresses

Fig.5 Comparison of simulations and experimental results for the condition of v=125m/min, f=0.15mm/r. (a) X-direction residual stresses; (b) Y-direction residual stresses

Fig.6 Comparison of simulations and experimental results for the condition of v=150m/min, f =0.2mm/r. (a) X-direction residual stresses; (b) Y-direction residual stresses

1	El-Axir M H. A method of modeling residual stress distribution in turning for different materials. International Journal of Machine Tools & Manufacture, 2002, 42(9): 1055–1063 https://doi.org/10.1016/S0890-6955(02)00031-7
2	Fuh K H, Wu C F. A residual-stress model for the milling of aluminum alloy (2014-T6). Journal of Materials Processing Technology, 1995, 51(1–4): 87–105 https://doi.org/10.1016/0924-0136(94)01355-5
3	Ee K C, Dillon O W Jr, Jawahir I S. Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius. International Journal of Mechanical Sciences, 2005, 47(10): 1611–1628 https://doi.org/10.1016/j.ijmecsci.2005.06.001
4	Merwin J E, Johnson K L. An analysis of plastic deformation in rolling contact. Proceedings of the Institution of Mechanical Engineers, 1963, 177(1): 676–690 https://doi.org/10.1243/PIME_PROC_1963_177_052_02
5	Jiang Y, Sehitoglu H. An analytical approach to elastic-plastic stress analysis of rolling contact. Journal of Tribology, 1994, 116(3): 577–587 https://doi.org/10.1115/1.2928885
6	Ulutan D, Erdem Alaca B, Lazoglu I. Analytical modelling of residual stresses in machining. Journal of Materials Processing Technology, 2007, 183(1): 77–87 https://doi.org/10.1016/j.jmatprotec.2006.09.032
7	Lazoglu I, Ulutan D, Alaca B E, et al. An enhanced analytical model for residual stress prediction in machining. CIRP Annals-Manufacturing Technology, 2008, 57(1): 81–84 https://doi.org/10.1016/j.cirp.2008.03.060
8	Su J C. Residual stress modeling in machining processes. Dissertation for the Doctoral Degree. Atlanta: Georgia Institute of Technology, 2006
9	Komanduri R, Hou Z B. Thermal modeling of the metal cutting process: Part I—Temperature rise distribution due to shear plane heat source. International Journal of Mechanical Sciences, 2000, 42(9): 1715–1752 https://doi.org/10.1016/S0020-7403(99)00070-3
10	McDowell D L. An approximate algorithm for elastic-plastic two-dimensional rolling/sliding contact. Wear, 1997, 211(2): 237–246 https://doi.org/10.1016/S0043-1648(97)00117-8
11	Waldorf D J. Shearing, ploughing, and wear in orthogonal machining. Dissertation for the Doctoral Degree. Urbana-Champaign: University of Illinois, 1996
12	Saif M T A, Hui C Y, Zehnder A T. Interface shear stresses induced by non-uniform heating of a film on a substrate. Thin Solid Films, 1993, 224(2): 159–167

[1]	Xinyu HUI, Yingjie XU, Weihong ZHANG. Multiscale model of micro curing residual stress evolution in carbon fiber-reinforced thermoset polymer composites[J]. Front. Mech. Eng., 2020, 15(3): 475-483.
[2]	Jinya KATSUYAMA, Shumpei UNO, Tadashi WATANABE, Yinsheng LI. Influence evaluation of loading conditions during pressurized thermal shock transients based on thermal-hydraulics and structural analyses[J]. Front. Mech. Eng., 2018, 13(4): 563-570.
[3]	Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG. Experimental study of surface integrity and fatigue life in the face milling of Inconel 718[J]. Front. Mech. Eng., 2018, 13(2): 243-250.
[4]	A. DAVOUDINEJAD, P. PARENTI, M. ANNONI. 3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6[J]. Front. Mech. Eng., 2017, 12(2): 203-214.
[5]	Angelos P. MARKOPOULOS,Ioannis K. SAVVOPOULOS,Nikolaos E. KARKALOS,Dimitrios E. MANOLAKOS. Molecular dynamics modeling of a single diamond abrasive grain in grinding[J]. Front. Mech. Eng., 2015, 10(2): 168-175.
[6]	Zhaoxu QI,Bin LI,Liangshan XIONG. The formation mechanism and the influence factor of residual stress in machining[J]. Front. Mech. Eng., 2014, 9(3): 265-269.
[7]	Zhaoxu QI,Bin LI,Liangshan XIONG. An improved algorithm for McDowell’s analytical model of residual stress[J]. Front. Mech. Eng., 2014, 9(2): 150-155.
[8]	Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI. Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite[J]. Front Mech Eng, 2013, 8(2): 187-200.
[9]	Meenu GUPTA, Surinder Kumar GILL. Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing[J]. Front Mech Eng, 2012, 7(4): 417-426.
[10]	Genghuang HE, Xianli LIU, Fugang YAN. Research on the dynamic mechanical characteristics and turning tool life under the conditions of excessively heavy-duty turning[J]. Front Mech Eng, 2012, 7(3): 329-334.
[11]	Subhash ANURAG, Yuebin GUO, . Predictive model to decouple the contributions of friction and plastic deformation to machined surface temperatures and residual stress patterns in finish dry cutting[J]. Front. Mech. Eng., 2010, 5(3): 247-255.
[12]	Yiliang ZHANG, Song YANG, Xuedong XU. Application of metal magnetic memory test in failure analysis and safety evaluation of vessels[J]. Front Mech Eng Chin, 2009, 4(1): 40-48.
[13]	LU Jinzhong, ZHANG Yongkang, KONG Dejun, REN Xudong, GE Tao, ZOU Shikun. Effects on mechanical properties in electron beam welding of TC4 alloy by laser shock processing[J]. Front. Mech. Eng., 2007, 2(4): 478-482.
[14]	XIE Qiu, YANG Yu, LI Xiaoli, ZHAO Ningyu. Basic model study on efficiency evaluation in collaborative design work process[J]. Front. Mech. Eng., 2007, 2(3): 344-349.
[15]	LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong. Cutting Force Model for a Small-diameter Helical Milling Cutter[J]. Front. Mech. Eng., 2007, 2(3): 272-277.

Viewed

Full text

Abstract

Cited

Shared

Discussed